By Valco Melton On 2025-11-04
A success story on how the German-based packaging company eliminated downtime and increased production efficiency by switching to AutoWheel techology.
Gundlach Verpackungen, a family-run packaging company founded in 1847, has long been committed to driving the transition from plastic to fiber-based packaging. With a clear mission to deliver sustainable solutions that meet the highest environmental standards, Gundlach produces folding cartons and roll products, such as wrapping, using offset, flexo, and gravure printing. Guided by the maxim “Knowledge in packaging,” the company continues to innovate in fiber-based solutions.
Glue wheel challenges
For years, like many manufacturers, Gundlach relied on glue wheel technology for carton gluing. However, the system presented ongoing challenges. “The main drawback of the glue wheel was always the daily cleaning effort, which required a considerable amount of time,” explains Gundlach. The open system needed to be cleaned every day, requiring operators to empty the adhesive tank each time. This process not only consumed time but also caused a daily loss of around one kilogram of adhesive. Over the course of a year, the result was significant waste, unnecessary cost, and a loss of production uptime.
Sven Heimann, Valco Melton Sales Representative, and Axel Baake, Process Engineer at Gundlach Verpackung.
AutoWheel: Presenting an efficient alternative
Valco Melton, a leading global manufacturer of adhesive dispensing and quality assurance systems with longstanding expertise in the paper converting industries, addressed this issue by presenting Gundlach with an innovative solution: a complete replacement of the glue wheel with the Valco Melton AutoWheel system.
The AutoWheel combines the reliability of traditional contact adhesive transfer technology
with the benefits of a fully enclosed adhesive dispensing system. In practice, this means no daily cleaning or tank emptying. The closed design eliminates the risk of adhesive degradation, or impurities reaching the tank, while the valve dispensing technology ensures precise glue placement, even at the highest operating speeds. This prevents the formation of ‘stickers’, or glue splashes outside the tab area, which can cause cartons to stick together. Additionally, you can rely on the system to not run out of glue and cause additional downtime and production loss.
A smooth installation by the team at Valco Melton Germany
As part of a global network that spans over 96 locations, Valco Melton has a local sales, service and support team in Düsseldorf, Germany. It was this local team that was able to provide Gundlach with direct support, listening to and understanding their needs, and deliver the AutoWheel system to eliminate costly downtime.
According to Gundlach, the installation was seamless. “It was completed in just a few hours, with no modifications to the production line,” they note. Operators adapted quickly and were enthusiastic from the very start. Since the installation, Gundlach has not had to contact technical support even once.
Proven Results: Eliminating downtime
After twelve weeks of operation, the impact on production has been striking. “Cleaning times have essentially dropped to zero, which has significantly increased machine productivity,” Gundlach reports. Downtime has been eliminated, resulting in higher production capacity. The plant now operates more efficiently and with greater flexibility.
The AutoWheel system ensures a clean and precise application, even at speeds above 600 m/min, actually exceeding the company’s need for production speed.
But what truly sets the system apart is its ability to completely remove cleaning downtime, directly boosting productivity. “We can now produce more in the same amount of time,” Gundlach concludes.
What’s Next
Looking ahead, Gundlach is already exploring the implementation of AutoWheel technology on additional lines. “Based on the experience we’ve had so far and the capabilities the solution offers, we are already discussing further systems with Valco Melton. For gluing, we rely entirely on Valco Melton. There is currently no better system on the market.”